WEATHERPROOF RAMP DOOR
An RV ramp door is hingedly connected near the vehicle floor for selective opening and closing by a user. A weather-resistant construction of a ramp door includes an inner foam body having an inner face and an outer face, a ramp door inner surface, a ramp door outer surface, a first layer of thermoplastic composite material disposed between the inner face of the foam body and the ramp door inner surface, and a second layer of thermoplastic composite material disposed between the outer face of the foam body and the ramp door outer surface. The ramp door inner surface may be a slip-resistant material, and the ramp door outer surface may be a fiberglass panel. The ramp door may include one or more weep holes for releasing any trapped liquid.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 63/128,980, filed Dec. 22, 2020, the entire content of which is herein incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT(NOT APPLICABLE)
BACKGROUNDThe invention relates to ramp doors of recreational vehicles or toy haulers and more particularly to weatherproofing a ramp door to protect it from water retention in extreme weather conditions.
Standard ramp doors that are constructed at least partially of wood can retain water and hold moisture that can remain trapped within the ramp door for nearly its entire lifespan. Water retention within the ramp door can deteriorate the materials at a faster rate and can affect the overall quality and function as well as cause the user to have to replace the door in a shorter period of time than anticipated. The user may have to rush to stow the ramp door in inclement weather or may even be limited to only using the ramp door in times of favorable weather conditions. This may especially cause frustration when the user is using the ramp door to load or unload ATVs, motorcycles, or other sporting equipment or if the user has the ramp door deployed as a patio.
SUMMARYIt has been long-desired to construct a ramp door to avoid or eliminate water retention after use in inclement weather. In some embodiments, the ramp door of the described embodiments is composed a foam interior encompassed by a polypropylene and fiberglass blended material with a woven material interior surface and a fiberglass exterior surface. The stacking of these materials creates a weatherproof ramp door that is water-resistant and does not retain moisture. The ramp door may also include weep holes for releasing any internal water.
The strength of the ramp door is comparable to existing constructions. The door of the described embodiments is water-resistant and therefore is less likely to deteriorate or be damaged at the same rate as existing constructions.
In an exemplary embodiment, a ramp door hingedly connected to a structure consists of a foam body having an inner face and an outer face, a ramp door inner surface, a ramp door outer surface, a first layer of thermoplastic composite material disposed between the inner face of the foam body and the ramp door inner surface, and a second layer of thermoplastic composite material disposed between the outer face of the foam body and the ramp door outer surface.
The ramp door may be connected to a recreational vehicle. The foam body may be an open celled foam. The ramp door inner surface may be a slip-resistant material, and the ramp door outer surface may be a fiberglass panel. The slip-resistant material may be wherein the slip-resistant material comprises a woven product or laminate material. In some embodiments, the thermoplastic composite material is 50% polypropylene and 50% fiberglass. The ramp door may further include at least one weep hole.
In another exemplary embodiment, a ramp door in a layered construction from an inside surface to an outside surface includes a first layer of thermoplastic composite material, a foam layer body directly connected to the first layer of thermoplastic composite material, and a second layer of thermoplastic composite material directly connected to the foam layer body. The layered construction is without any wood or any product containing wood.
In yet another exemplary embodiment, a method of making a weather-resistant ramp door includes the steps of mounting a first layer of thermoplastic composite material on one of the inner face or the outer face of the inner foam body; mounting a second layer of thermoplastic composite material on the other of the inner face or the outer face of the inner foam body; mounting a slip-resistant material onto the layer of thermoplastic composite material that is mounted to the inner face of the inner foam body, compressing the thermoplastic composite material between the slip-resistant material and the inner foam body; mounting a fiberglass panel onto the layer of thermoplastic composite material that is mounted to the outer face of the inner foam body, compressing the thermoplastic composite material between the fiberglass panel and the inner foam body; and securing a metal extrusion about the periphery of the ramp door.
These and other aspects and advantages will be described in detail with reference to the accompanying drawings, in which:
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Due to the change in stacking of materials, the ramp door 10 of the described embodiments is completely water-resistant and prevents or precludes retention of water within the structure, therefore protecting the structure from damage and deterioration. The implementation of a second layer of thermoplastic composite material 18 may reduce weight of the ramp door 10. The ramp door may also include weep holes for releasing any internal water.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
Claims
1. A ramp door hingedly connected to a structure, the ramp door consisting of:
- a foam body having an inner face and an outer face;
- a ramp door inner surface;
- a ramp door outer surface;
- a first layer of thermoplastic composite material disposed between the inner face of the foam body and the ramp door inner surface; and
- a second layer of thermoplastic composite material disposed between the outer face of the foam body and the ramp door outer surface.
2. A ramp door according to claim 1, wherein the ramp door is connected to a recreational vehicle.
3. A ramp door according to claim 1, wherein the foam body is an open celled foam.
4. A ramp door according to claim 1, wherein the ramp door inner surface comprises a slip-resistant material.
5. A ramp door according to claim 4, wherein the slip-resistant material comprises a woven product or laminate material.
6. A ramp door according to claim 1, wherein the ramp door outer surface comprises a fiberglass panel.
7. A ramp door according to claim 1, wherein the thermoplastic composite material comprises 50% polypropylene and 50% fiberglass.
8. A ramp door according to claim 1, further comprising at least one weep hole.
9. A ramp door in a layered construction from an inside surface to an outside surface, the ramp door comprising:
- a first layer of thermoplastic composite material;
- a foam layer body directly connected to the first layer of thermoplastic composite material; and
- a second layer of thermoplastic composite material directly connected to the foam layer body,
- wherein the layered construction is without any wood or any product containing wood.
10. A ramp door according to claim 9, further comprising a slip-resistant material connected directly to the first layer of thermoplastic composite material, and further comprising a fiberglass panel connected directly to the second layer of thermoplastic composite material.
11. A ramp door according to claim 9, wherein the foam layer body is an open celled foam.
12. A ramp door according to claim 9, wherein the first and second layers of thermoplastic composite material comprise a non-woven material of 50% polypropylene and 50% fiberglass.
13. A ramp door according to claim 9, wherein the foam layer body is connected to the first layer of thermoplastic composite material via a first adhesive layer, and wherein the second layer of thermoplastic composite material is connected to the foam layer body via a second adhesive layer.
14. A ramp door according to claim 13, further comprising a metal extrusion secured around a periphery of the layered construction.
15. A method of making a weather-resistant ramp door, the ramp door including an inner foam body having an inner face and an outer face, the method comprising:
- (a) mounting a first layer of thermoplastic composite material on one of the inner face or the outer face of the inner foam body;
- (b) mounting a second layer of thermoplastic composite material on the other of the inner face or the outer face of the inner foam body;
- (c) mounting a slip-resistant material onto the layer of thermoplastic composite material that is mounted to the inner face of the inner foam body, compressing the thermoplastic composite material between the slip-resistant material and the inner foam body,
- (d) mounting a fiberglass panel onto the layer of thermoplastic composite material that is mounted to the outer face of the inner foam body, compressing the thermoplastic composite material between the fiberglass panel and the inner foam body; and
- (e) securing a metal extrusion about a periphery of the ramp door.
16. A method according to claim 15, further comprising forming weep holes in the ramp door.
17. A method according to claim 16, wherein the step of forming weep holes in the ramp door comprises forming the weep holes adjacent a bottom of the ramp door and adjacent the metal extrusion.
Type: Application
Filed: Dec 17, 2021
Publication Date: Jun 23, 2022
Inventors: Frank A. Zappia, III (Mishawaka, IN), Josh Black (Osceola, IN), Joshua T. Howk (Elkhart, IN), Scott C. McKinnon (Union City, MI)
Application Number: 17/554,733